System and method for flexible sealant with density modifier

ABSTRACT

The disclosed latex system comprises a one-component, closed-cell, semi-foam, mastic sealant using gas-filled, flexible, organic microspheres to create a product that is elastic and compressible under pressure without protruding in an outward direction when compressed, thereby allowing the applied sealant to compress in an enclosed, maximum-filled channel unlike typical mastic sealants (while retaining the ability to rebound). This allows the sealant to function as a gasket, and, once fully cured, to have properties including vibration damping, insulating, and condensation resistance. The sealant can be formulated as an air barrier or a vapor barrier and at various degrees of moisture resistance. It may be applied by different packaging variations including aerosol can (bag in can or bag on valve), airless sprayer, cartridge tubes, foil tubes, squeeze tubes, and buckets to be applied using a brush, trowel, spatula, etc. The disclosed mastic sealant can also be formulated to be smoke-resistant and flame-resistant.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. 120, this application is a continuation of U.S.patent application Ser. No. 15/388,841, entitled “System and Method forFlexible Sealant with Density Modifier,” filed Dec. 22, 2016, and namingSandra Kocurek, Devin Kocurek, and Jonathan Perriello as inventors,which is a non-provisional of U.S. Provisional Patent Application Ser.No. 62/273,970, entitled “System and Method for Flexible Sealant withDensity Modifier,” filed Dec. 31, 2015, and naming Sandra Kocurek, DevinKocurek, and Jonathan Perriello as inventors, the disclosures of whichare incorporated herein by reference in their entirety.

FIELD

The present disclosure relates generally to sealant compounds. Morespecifically, but not by way of limitation, the present disclosurerelates to a system and method for a flexible sealant with a densitymodifier and optional flame resistance.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Conventional sealants do not contain sufficient structural propertiesfor all desired uses or methods of application. For example, when cured,typical one-component mastic sealants are limited in compressibility andtend to deform in a direction outward from the bead line in which theyare applied. Typical mastic sealants are also too rigid to create anadequate sealing gasket for building materials such as, for example,gypsum drywall. Although high-movement elastomeric sealants have ahigher extension capability, they are unable to compress withoutprotruding in some other direction and, therefore, cannot compress in aclosed, maximum-filled chamber (e.g., a can). Additionally, when manyspray foams are cured, breaching the skin of the cured foam compromisesthe foam's integrity, thereby reducing or nullifying the ability of thefoam to provide an adequate seal.

Regarding application, two-component spray foams are dependent onoff-gassing chemicals such as isocyanates that are known allergens andsensitizers, and other spray foams often utilize highly flammablepropellants making them especially undesirable for fire- andsmoke-resistant applications. Two-component spray foam systems oftenrequire specialized application tools. Such foam systems may result indifficulty in controlling uniformity in cell size and cleaning theapplication equipment or foam over-spray. As such, there is a desire forother sealant compounds.

SUMMARY

In one embodiment, the present disclosure provides a sealant compositioncomprising: up to about 80 vol % of a polymeric dispersion; from about20 vol % to about 65 vol % of a density modifier; and from about 0 vol %to about 10 vol % of one or more additives.

In another embodiment, the present disclosure provides a method ofmanufacturing a sealant composition, the method comprising: mixing aliquid and additives, wherein the additives comprise from about 0 vol %to about 10 vol % of the sealant composition; dosing a polymericdispersion into the mix of liquid and additives, wherein the polymericdispersion comprises up to about 80 vol % of the sealant composition;and dosing a density modifier, wherein the density modifier comprisesfrom about 20 vol % to about 65 vol % of the sealant composition.

Further embodiments and apparatuses, including other areas ofapplicability, will become apparent from the description providedherein. It should be understood that the description and specificexamples are intended for purposes of illustration only and are notintended to limit the scope of the present disclosure in any manner.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments are illustrated by way of example in the accompanyingfigures not necessarily drawn to scale, in which like numbers indicatesimilar parts, and in which:

FIG. 1 illustrates a flowchart of an example method for manufacturingthe disclosed composition.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are setforth to provide a thorough understanding of the present disclosure.However, those skilled in the art will appreciate that the presentdisclosure may be practiced, in some instances, without such specificdetails. Additionally, for the most part, specific details, and thelike, have been omitted inasmuch as such details are not considerednecessary to obtain a complete understanding of the present disclosure,and are considered to be within the understanding of persons of ordinaryskill in the relevant art.

The present disclosure provides, in some embodiments, a productcomposition that is a latex system comprising a one-component,closed-cell, semi-foam, mastic sealant using gas-filled, flexible,organic microspheres to create a product that is elastic, compressibleunder pressure (while retaining the ability to rebound), able tofunction as a gasket, and, once fully cured, has properties that includevibration damping, insulating, and condensation-resistant. In someembodiments, the disclosed product composition can be applied bydifferent packaging variations for differing constructional needs. Suchpackaging variations include, for example, an aerosol can (bag in can orbag on valve), cartridge tubes, foil tubes, squeeze tubes, and bucketsto be applied using a brush, trowel, spatula, airless sprayer, etc. Insome embodiments, the disclosed product composition can also beformulated to be smoke-resistant and flame-resistant to meet variousbuilding codes. Furthermore, unlike typical mastic sealants, thedisclosed product composition can be formulated to have a highercompression capability than extension capability, thereby allowing theapplied composition to compress without deforming in directions outsideof its applied bead line.

As discussed herein, the disclosed product composition may be formulatedfor use in many fields of application. For example, in one or moreembodiments disclosed herein, the product composition may be formulatedas a sealant or coating for ventilation ducts, joints, cracks, gaps,pipe and cable penetrations, gypsum drywall, and other areas ofapplication. In other embodiments, the product composition may beformulated as an adhesive, for example, for parquet, wood flooring, orother applications. In some embodiments, the disclosed productcomposition may be formulated to provide joint/structural vibrationdamping, to provide insulation, for anti-condensation uses, or forsmoke- and flame-resistant applications.

In some embodiments, vibration damping characteristics allow the productto be used to reduce noise transmission when sealing gaps or adheringsubstrates by dissipating the sound vibrations and reducing theiraudible noise detection. Examples include sealing gaps in wall cavitiesthat would otherwise allow sound to freely travel, or adhering flooringsuch as parquet flooring to a subfloor to reduce the noise transmissionwhen objects strike the floor. The vibration damping characteristics,and the capability of the composition to compress and deform in multipledirections without protruding in another direction, allows thecomposition to perform well as a sealant in a seismic joint system. Asdiscussed herein, the ability of the composition to compress and/ordeform without protruding means that the composition, when compressed ordeformed in a particular direction, does not respond to the force of thecompression or deformation of the composition by extending or expandingoutwardly from the composition, but instead compresses internally due tothe compressibility of the microspheres. This ability of the compositionto be compressed under applied pressure in a cured film or bead withoutprotruding out from the original cured form provides good gasketproperties, even in an enclosed gap or channel.

The composition is capable of compression in both the wet phase and inits cured state. Generally, the wet-phase composition is capable ofachieving a range of compression of about 15% to about 45% of thewet-phase volume of the composition. This allows the composition to becompressed in a closed chamber, such as an aerosol can, to achievegreater amounts of the product in the closed chamber than would beachievable with the uncompressed composition. In other words, thecomposition, in its wet phase, may be compressed (e.g., by about15%-45%) to fit a greater amount of the composition in the closedchamber. When in its cured state, the composition is capable ofachieving a range of compression of about 50% to about 95% of thecomposition's cured volume (e.g., the size of an applied compositionbead or film), while maintaining the ability to rebound to the originalcured volume (e.g., the original size of the applied composition bead orfilm). By way of contrast, other sealant compositions cannot becompressed in the manners discussed herein and, therefore, cannotachieve these effects.

In some embodiments, the disclosed product composition may be formulatedto produce an aqueous or non-aqueous product that is a cross between atypical mastic sealant and a cellular foam product. In order to producesuch products, various components are used to develop the backbone thatsupports the semi-foam final product. These various components mayinclude: a polymeric dispersion; a surfactant package; a biocidepackage; a freeze/thaw package; rheology modifying additives; pHmodifying additives; a defoamer additive; a plasticizer additive; acoalescing agent; various fillers; adhesion promoters (coupling agents);and, in some embodiments, smoke- and flame-resistant additives. In someembodiments, these various components are combined with a high level ofgas-filled, flexible microspheres to produce the disclosedone-component, semi-foam product composition. In some embodiments, themicrospheres may include, for example, Dualite® (e.g., Dualite®E065-135D), Expancel® (e.g., Expancel® 909 DET 80 d15 or MI90 DET 80d15), and combinations thereof.

In some embodiments, the polymeric dispersion can be selected towithstand heavy loading with fillers, including the gas-filledmicrospheres. The polymeric dispersion is typically based upon acrylicsor polyacrylates, but is not limited to these. Some examples of possibledispersions include: vinyl acrylic, styrenated acrylic, vinyl acetate,vinyl chloride, vinylidene chloride, ethylene vinyl acetate, butadienestyrene, butadiene acrylonitrile, acrylate acrylonitrile, and otherdispersions of polymers and copolymers. Some non-aqueous optionsinclude: urethanes, silicones, polysulfides, styrene butadiene, SBSblock copolymers, isoprene, silyl modified polyether, silyl modifiedpolyurethane, and others.

The choice of polymeric chemical composition may depend upon theintended end use of the product. For example, lower cost/performanceproducts that can function with lower movement and compressionattributes may use the higher-Tg (glass transition temperature),lower-cost polymeric raw materials. Applications for medium movement andcompression applications may use medium performance polymeric rawmaterials. Similarly, applications for higher movement and compressionapplications may use higher performing polymeric raw materials. In someembodiments, small particle size, low-Tg elastomeric polymer dispersionsresult in optimum performance for the finished product composition.Examples of such formulations are provided below in Tables 1-6.

In some embodiments, the surfactant package is selected to aid inprotecting the polymeric dispersion and wet out the fillers for shelflife stability. In some embodiments, the surfactant package also aidesin the distribution of the particles in the liquid phase to produce astable formulation that has viscosity stability and does not separate.This includes a wetting/emulsifying surfactant that is selected to becompatible with the polymeric dispersion, and to have the appropriatehydrophilic-lipophilic balance (HLB) value and melt point to support thefinished product through electrolyte and mechanical stabilization of thepolymer.

In some embodiments, the surfactant can be cationic, anionic, nonionic,Gemini (dimeric), or a combination thereof. Examples of such surfactantsinclude: alkylphenol ethoxolate (APEO) (triton x-405) or APEO free suchas Carbowet® 109, ZetaSperse® 179, Disponil® AFX 4070, and combinationsthereof. In some embodiments, the surfactant is nonionic and,preferably, APEO (alkylphenol ethoxolate) free.

The surfactant package includes a dispersant that deflocculates thesolids within the formulation allowing increased loading levels andfurther stabilization. Depending upon the chosen fillers, whetherinorganic and/or organic, the dispersant can be low molecular weight orhigh molecular weight. Low molecular weight dispersants are generallymore compatible with inorganic fillers. In some embodiments, especiallywhen using clay fillers, a secondary dispersant such as tetrasodiumpyrophosphate (TSPP) or potassium tripolyphosphate andydrous (KTPP) areused to further increase the stability of the fillers and preventre-agglomeration or flocculation. In some embodiments, such as for thishighly filled type of formulation, the high molecular weight dispersantmay be chosen for increased stability due to higher steric hindrance ofre-agglomeration. Polyacrylates are preferred, in some embodiments, withanchoring groups that absorb onto the surface of the organic fillerthrough hydrogen bonding, dipole-dipole interactions, and London-Van derWaals forces, which creates a strong steric hindrance to preventre-agglomeration and also aids with inorganic fillers due to the highnumber of bound sites. The stability provided by the surfactants aidesfreeze/thaw stability.

In some embodiments, the biocide package is selected to protect theproduct composition in the in-can wet phase as well as the cured-film(dry film) phase from bacterial, fungus, and mildew attack during theshelf life and service life of the product under normal storage andusage conditions. In some embodiments, a broad spectrum biocide ischosen for the wet phase protection to keep away microbial growth ofbacteria, fungi, and algae during the manufacturing, packaging, andin-can lifespan of the final formulation. In some embodiments, a low- orzero-VOC product is used. Examples of a low-VOC product include Mergal®758 or Mergal® K12N. A second broad spectrum (a dry film phase) biocidemay be chosen, in some embodiments, to protect the cured film frommicrobial attach from bacteria, fungi, mold, and mildew. In someembodiments, the second broad spectrum biocide (i.e., dry film phasebiocide) may include a low- or zero-VOC product. Examples of a zero-VOCproduct include Polyphase® 678, or zinc oxide. Optimum protectionloading levels may be tested by thorough microbiological testing.

In some embodiments, the freeze/thaw package is selected to protect theproduct composition during its storage shelf life from five or morefreeze/thaw cycles resulting from ambient temperatures dropping below32° F. The freeze/thaw package can be selected from a group of variousfreeze/thaw agents including ethylene glycol, propylene glycol,methanol, Rhodoline FT100, urea, and others. Although glycols arecommon, in some embodiments, urea may be preferred due to its zero-VOCcontent. In some formulations, urea may act as an aide for smoke andflame resistance due to its ability to function similar to a blowingagent for an intumescent package of raw materials, rather than as a fuelsource.

In some embodiments, the rheology modifying additives are selected toadjust the rheology as needed to reach a specific viscosity and flow ofthe finished product to meet application requirements. These rheologymodifying additives can include alkali swellable emulsions (ASE),associative thickeners, cellulosic thickeners, fumed silica thickeners,modified caster oils, clays, polyamides, and specialty mineral-basedthickeners. In some embodiments, the selected rheology modifyingadditives and loading level may be dependent upon desired finalperformance characteristics such as rheology (thixotropic,thermoplastic, pseudoplastic, dilantant), slump resistance, hydrophilicor hydrophobic performance, sprayability, extrudability, brushability,and others.

In some embodiments, pH modifying additives may be selected to helpstabilize the polymeric dispersion and/or activate the rheologymodifier. These pH modifying additives can include ammonium hydroxide,potassium hydroxide, caustic soda, sodium silicate, Advantex, Vantex T,AMP, AMP-95, MEA, DEA, TEA, KOH, and others. In some embodiments, theselected pH modifying additives and loading level may be dependent uponseveral factors including, for example, system compatibility; substratecompatibility; and desired final performance characteristics such as VOCcontent; staining resistance; and, in the case of sodium silicate, someassistance with smoke and flame resistance due to its ability tointumesce. In some embodiments, it may be preferred to use a pH modifierthat is not a VOC contributor. For smoke- and flame-resistantformulation, the pH modifier additives may include a solution of water,caustic soda, and sodium silicate.

In some embodiments, the defoamer additive is used to aide in reductionof any air entrapment during the manufacturing, packaging, and storageof the product that can lead to fracture points in a highly filledsystem which can then diminish the cohesive strength in the final film.This can include insoluble mineral oils, silicones, certain alcohols,stearates, and glycols. In embodiments for water-borne sealants, thedefoamer additive may be mineral-oil based.

In some embodiments, the plasticizer additive may be used to impartflexibility, flowability, softness, reduce brittleness, and in somecases, increase the resistance to smoke and flame. The plasticizeradditive may include a variety of options including benzoates,phthalates, phosphate esters, and others. An example of such aplasticizer may include, for example, Santicizer® 148. To avoidplasticizer migration issues and potential staining issues, a polymericbinder that does not require the use of plasticizers may be used in thefinal system.

The coalescing agent may be used, in some embodiments, to soften thepolymeric binder, lower the minimum film forming temperature, and allowthe polymeric binder to flow as water leaves the sealant to create anoptimum film. In some embodiments, the coalescing agent solvates thepolymeric binder, evaporates slower than the water, and has lowsolubility in water. In some embodiments, use of a binder that does notrequire a coalescing agent may keep the volume solids of the sealanthigh.

Various fillers may be used to add various attributes to the finalformulation of the product composition. Such attributes include: airblocking, structural reinforcement, moisture resistance, condensationcontrol, thermal resistance, smoke and flame resistance, softness,viscosity build, reduced shrinkage, altered density, changedelectro-conductivity, improved scrub resistance, reduced tack, alteredoptical properties, altered permeability, color, vibration dampening,insulating, and others.

For example, in some embodiments, it may be desirable to use aparticular filler to provide a pigment for coloring the composition fordifferent applications. For example, iron oxide may be used as a fillerto give the compound a red color when the composition is formulated as afirestop. In other embodiments, a particular filler may be used tocolor-match the formulation to a specific application. For example, apaint or stain may be added to the formulation as a filler such that thecomposition, when applied and/or cured, achieves a particular color.

In some embodiments, the composition may be modified to achieve aparticular textural appearance. For example, the composition may bemodified to have a gritty texture that matches the appearance of mortarwhen dried. This embodiment may be useful for filling pipe penetrationsin brick, such as around exterior faucets, because the composition canprovide the flexibility and other sealant properties discussed hereinwhile also giving the appearance that the pipe penetration is filledwith mortar. In some embodiments, the appearance of mortar may beachieved by using large-particle-size, compressible microspheres andreplacing some of the filler in the base formula with a combination ofcoarse fillers (such as hollow ceramic microspheres) that give theappearance of mortar sand (e.g. Fillite or Extendospheres) but stillallow the end product to retain the light weight density. To furtherenhance the appearance of mortar, a hollow, colored, light-weight sphere(such as, for example, the phenolic Phenoset sphere) can be added insmall quantities for the appearance of red brick sand specs while stillmaintaining a low density in the sealant. In some embodiments, graphiteor color-coated, mica black specs can be added for the appearance ofblack sand specs. Alternately, irregular-shaped, matted, plastic orpolymeric chips or glitter can be added to simulate reddish and blacksand specs. As mentioned above, in such embodiments, the end product hasthe appearance of mortar, but the flexibility and compressibility of asemi-foam sealant that can withstand pipe movement when attaching a hoseto a faucet or other penetrations that may have pipes that move orvibrate during use.

In some embodiments, fillers such as mica, aluminum trihydrate (ATH),and/or magnesium hydroxide may be used for smoke- and flame-resistantformulations of the product composition. Mica contributes to suspension,reduced cracking, reduced shrinking, increased moisture resistance,added heat resistance, increased stiffness without compromising flexuralstrength, low coefficient of expansion and heat dimensional stability,anti-vibration, sound damping, and insulating properties. ATH andmagnesium hydroxide decompose endothermically which leads to atemperature reduction and functions as a heat sink to retard pyrolysisand burn rate. The water that is released during decomposition dilutescombustion gases and toxic fumes. Smoke suppression is thereby achievedthrough this process. The aluminum trihydrate decomposes at a lowertemperature than the magnesium oxide. Combining the two into thesemi-foam further suppresses the smoke development in a synergisticmanner.

For a semi-foam product composition that does not need to meet a smoke-and flame-retardant specification, a range of different fillers areoptional depending on the end product's application requirements. Thesefillers may include talc, calcium carbonate, kaolin clays, calcinedclays, fumed silica, precipitated silica, carbon black, graphite,ceramic microspheres, phenolic microspheres, glass microspheres,alumino-silicate microspheres and others. Examples of these formulationsare provided below in Tables 1-6.

In some embodiments, adhesion promoters or coupling agents may be usedto increase the adhesion of the product composition to variousdifficult-to-adhere-to substrates and to enhance moisture resistance. Insome embodiments, this selection of adhesion promoters may be based onsilane or stabilized non-toxic metal/organofunctional chemistry. In someembodiments, the addition of an adhesion promoter or coupling agentreduces the moisture at the substrate/sealant interface, and improvesmoisture resistance, temperature resistance, chemical resistance, and/orbinds the organic polymers to the mineral or siliceous fillers.

In some embodiments, smoke- and flame-resistant additives may be used tocreate sealants that meet fire code regulations. In such embodiments,the selection of additives used affects the product composition'sability to meet specific requirements of varying building codes. In someembodiments, the semi-foam product composition contains a high loadinglevel of gas-filled microspheres, which intuitively suggests that thefinal formulation would be a high risk for fire when the binder and thefiller are potential fuel sources for a flame, unless the binder isflame resistant, as in the case of halogenated polymers. One embodimentincludes choosing a halogenated binder, and selecting the otherconstituents around this choice. Thus, for binders that are nothalogenated, all other choices may be more impactful during the rawmaterials selection process to avoid providing a fuel source, ratherthan smoke- and flame-retardant.

In some embodiments, a smoke- and flame-retardant semi-foam sealantincludes aluminum trihydrate and/or magnesium hydroxide along with micafor fillers. Adding ammonium polyphosphate or ammonium phosphate mayfurther increase the smoke- and flame-retardant properties in someembodiments. Using prilled urea, in some embodiments, for thefreeze/thaw agent also provides a blowing agent in the presence of acarbon source and an acid source to provide some intumescent properties.Using sodium silicate as part of a pH modifying solution (e.g., solutionof water, sodium silicate, and caustic soda) may also provide someintumescent properties. In some embodiments, using acrylonitrile- orstyrenated-acrylic-based polymers as an alternative to halogenatedpolymers resists flame spread.

In some embodiments, it may be preferable to avoid the use of coalescingagents, plasticizers, and glycols to reduce added fuel sources to thesmoke- and flame-retardant semi-foam sealant. In such embodiments, itmay be preferable to use thickeners that are not fuel sources such aslaponite, attapolgite, bentonite, or others.

In some embodiments, the addition of expandable graphite greatlyincreases the smoke and flame resistance through intumescent response toheat. Using the expandable graphite in conjunction with optimum fireresistant additives and the light weight compressible gas-filledmicrospheres may result in a light-weight, highly compressible,gasketing, semi-foam sealant that can function as a firestop and/or fireretardant sealant with added features such as anti-condensating surface,vibration damping, sound damping (acoustical absorption), and insulatingproperties. Further advantages are disclosed herein. Sample formulationsmay be found in Tables 1-6.

In addition to variations of the foregoing components, a high level ofgas-filled, flexible microspheres may be included to change the sealantinto a one-component, semi-foam product composition with one or more ofthe performance characteristics disclosed herein. In some embodiments,the amount of microspheres is about 20 to 65 percent microspheres byvolume. In some embodiments, the shell of the microsphere includes athermoplastic polymer, typically constructed of acrylonitrile, copolymerof acrylonitrile, and other acrylics, vinylidene chloride, or methylmethacrylate. The shell may be created by encapsulating a blowing agentsuch as isopentane or isobutene (or similar gas with a boiling pointlower than the softening point of the microsphere shell) with thepolymeric shell material and expanding the shell by heating the mixture.This allows the polymeric shell to soften and the blowing agent toexpand. Once cooled, the shell maintains the expanded diameter.

The shell of the microsphere can be coated with calcium carbonate orremain uncoated. Due to the polymeric nature of the shell, the expandedmicrospheres can be deformed or compressed without rupturing. When thecompressed microspheres are returned to an ambient pressure state, theyrebound back to their original expanded shape. In some embodiments, thecompressibility of the microspheres allows the product to compress up to45% in the liquid phase in a container, and up to 95% once applied andfully cured. This compressible attribute allows the semi-foam sealant tobe applied via spray despite the high volume solids content of thefinished product. It also allows the finished product to be heavilyloaded under pressure into an aerosol at a higher sealant volume thanthe actual physical volume of the aerosol can to maximize the appliedlinear footage of the sealant upon application, when compared tonon-compressible sealants. The compressibility also allows a high volumesolids sealant to be applied by an aerosol can with extended coverage.This compressibility also allows the product to be molded or tooledafter being applied without losing its sealing properties. This isbecause the foam is based on closed cell technology.

The final product composition can use one or a combination of multiplegrades of microspheres to reach the desired balance of compressibility,elongation, cohesive strength, and density. In some embodiments, themicrospheres have a particle size ranging from 15 μm to 200 μm. In someembodiments, the preferred particle size range is from 60 μm to 90 μmwith a density of approximately 0.015 g/cm³ to create a good balance ofattributes in the finished product. In some embodiments, themicrospheres have a density ranging from about 6.5 kg/m³ to about 100kg/m³. These specifications allow a finished product composition that,once applied and cured, becomes a syntactic foam product with theability to be compressed 50 to 95% of its original bead size withoutdeformation in a direction outward from the cured sealant bead diameter,and to then rebound once the applied pressure is released. Thisfunctionality gives the finished, cured product the ability to beelastic, compressible, vibration damping, gasketing, insulating, andanti-condensating. Additionally, the product composition has sufficientcohesive strength to perform well for various applications including inareas prone to vibrating, shifting, or otherwise moving. The product canbe applied in multiple delivery systems including sprayable systems suchas airless sprayers and aerosol cans, and other systems such as brush,trowel, spatula, cartridge tube, foil tube, and squeeze tube. Withspecial selection of raw materials and the addition of fire retardantadditives, the cured finished product can also be formulated to be afire retardant or firestop sealant.

In some embodiments, the finished product composition results in amastic sealant that is greater than 70% solids by volume, with theability to be applied by spray application.

In some embodiments, the latex system is highly loaded with gas-filledmicrospheres resulting in a highly filled mastic sealant that does notrequire plasticizer, thereby improving resistance to staining,eliminating plasticizer migration, eliminating plasticizer off-gassing,and improving compatibility with substrates such as CPVC.

In some embodiments, the latex system is highly loaded with gas-filledmicrospheres resulting in a highly filled sealant that does not requirecoalescing agents for film formation and has improved compatibility withsubstrates such as CPVC.

In some embodiments, the latex system is highly loaded with gas-filledmicrospheres that can be formulated to be a light-weight, compressible,flexible firestop and/or fire retardant sealant.

The following tables provide various example formulations. Table 1 is anexample formula for a product having a density of 0.57 g/cm³. Theformula in Table 1 is an aqueous formulation capable of over 85%compression. It may be used for sealing cracks, is excellent for aerosolcan application, is moisture resistant, and is an excellent base formulafor outdoor applications such as filling pipe penetrations, mortarrepair, etc. The formula in Table 1 exhibits the various attributeslisted with the exception of smoke and flame resistance. It is excellentfor sealing in buildings with known joint movement, is acceptable toaddition of pigments for aesthetic appearance, and is compatible withCPVC piping.

TABLE 1 Raw Material % % Category Raw Material Weight Volume AcrylicPolymer Rhoplex EC-3814 85.14 46.92 Diluent Water 5.91 3.36 DefoamerFoamaster 75 0.69 0.46 Surfactant Carbowet 109 1.02 0.54 BiocidePolyphase 678 0.20 0.09 Biocide Mergal K12N 0.30 0.16 Freeze/ThawAdditive, Prilled Urea 2.20 0.94 Blowing Agent Dispersant Orotan 731 dp0.39 0.34 Microspheres Expancel 909 1.22 46.21 DET 80 d15 Filler TalcMP4526 1.97 0.40 HASE Polyphobe TR115 0.37 0.20 pH Modifier Ammonia 0.590.37 100 100

Table 2 is an example formula for a product having a density of 0.52g/cm³. The formula in Table 2 is an aqueous formulation capable of over87% compression. It may be used for sealing cracks, is excellent foraerosol can application, is moisture resistant, and is an excellent baseformula for outdoor applications such as filling pipe penetrations,mortar repair, etc. and exhibits the various attributes listed with theexception of smoke and flame resistance. This formula may be excellentfor sealing in buildings with known joint movement, is acceptable toaddition of pigments for aesthetic appearance, and is compatible withCPVC piping. The formula exhibits increased adhesion to difficultsubstrates, increased moisture resistance, increased UV resistance, highvolume solids for minimal shrinkage and fast cure, and has extremely lowdensity.

TABLE 2 Raw Material % % Category Raw Material Weight Volume AcrylicPolymer Rhoplex EC-3814 81.61 40.96 Defoamer Foamstar 2420 0.34 0.20Surfactant Disponal AFX 4070 1.12 0.54 Biocide Polyphase 678 0.18 0.08Biocide Mergal 758 0.34 0.16 Functional Filler Aerosil 200 0.22 0.05Freeze/Thaw Additive, Prilled Urea 3.35 1.30 Blowing Agent DispersantOrotan 731 dp 0.36 0.29 Microsphere Expancel 909 1.57 53.97 DET 80 d15Filler Talc MP4526 6.71 1.24 Adhesion Promoter/ Organosilane 0.18 0.09Coupling Agent KBM 403 Functional Filler Titanium Dioxide 2.46 0.32 HASEThickener TT-615 0.56 0.27 pH Modifier 20% Caustic Soda 1.01 0.54 100100

Table 3 is an example formula for a product having a density of 0.51g/cm³. This formula is an aqueous formulation capable of over 85%compression with the listed attributes, including smoke and flameretardant properties. It has potential additional use as a light-weightfirestop sealant with the ability to apply from an aerosol can orairless sprayer as well as typical application methods. This formula maybe CPVC pipe compatible.

TABLE 3 Raw Material % % Category Raw Material Weight Volume AcrylicPolymer Rhoplex EC-3814 78.85 39.03 Defoamer Foamstar 2420 0.32 0.19Surfactant Disponal AFX 4070 1.08 0.51 Biocide Polyphase 678 0.17 0.07Biocide Mergal K12N 0.28 0.14 Functional Filler Aerosil 200 0.22 0.05Freeze/Thaw Additive, Prilled Urea 3.24 1.24 Blowing Agent DispersantOrotan 731 dp 0.35 0.27 Carbon Black Pigment Black Dye 0.06 0.03Dispersion Multijet 707 Microsphere Expancel 909 1.62 55.10 DET 80 d15Expandable Graphite Asbury 3626 9.72 2.21 Adhesion Promoter/Organosilane 0.19 0.09 Coupling Agent KBM 403 Functional Filler TitaniumDioxide 2.38 0.30 ASE Viscoatex 730 0.54 0.26 pH Modifier 20% CausticSoda 0.97 0.51 100 100

Table 4 is an example formula for a product having a density of 0.69g/cm³. This formula is an aqueous formulation capable of over 80%compression. It may be used indoors, and allows for easy-to-clean forapplication equipment, and over-spray. This formula is excellent forfire resistance sealant in areas that need to meet building codes, isgreat for building with known joint movement, is acceptable to additionof pigments for aesthetic appearance, and is compatible with CPVCpiping. This formula may be applied from an aerosol can or airlesssprayer as well as typical application methods. The formula haspotential additional uses such as parquet flooring adhesive. The productremains flexible at zero degrees Fahrenheit. Due to the choices ofpolymer, fillers, and additives, this formulation performs as a good airbarrier with a standard permeance (perms) of 21 and thermal insulatingattributes, has a VOC content of zero according to Method 24 testing,and an elongation at break of 214%.

TABLE 4 Raw Material % % Category Raw Material Weight VolumeAcrylate-Acrylonitrile Acronal 81 D 61.71 40.36 Copolymer Diluent Water3.61 2.50 Defoamer Foamstar 2420 0.17 0.13 Surfactant Disponil AFX 40701.19 0.82 Biocide Polyphase 678 0.12 0.07 Biocide Mergal 758 0.28 0.19Freeze/Thaw Additive, Prilled Urea 2.09 1.08 Blowing Agent DispersantTamol 851 0.95 0.55 Color Pigment Dispersion Phthalo Blue - 0.36 0.21Plasticolors Microsphere Expancel 909 1.07 44.26 DET 80 d15 AP FlameRetardant JJAZZ(4MA2) 3.04 1.59 Functional Filler Mica WG325 6.66 1.64Functional Filler/Smoke Aluminum Trihydrate 15.22 4.40 and FlameRetardant SB432 ASE Thickener Thickener P-1172 1.52 0.99 pH Modifier 20%Caustic Soda 2.02 1.21 100 100

Table 5 is an example formula for a product having a density of 0.67g/cm³. This formula is an aqueous formulation capable of over 80%compression with the listed attributes, including smoke and flameretardant properties. It has potential additional use as a light-weightfirestop sealant with the ability to apply from an aerosol can orairless sprayer as well as typical application methods. This formula isCPVC pipe compatible, has good adhesion to metal, and exhibits extremelylow to no slump when applied.

TABLE 5 Raw Material % % Category Raw Material Weight Volume AcrylicPolymer Rhoplex EC-3814 72.45 47.19 Diluent Water 5.03 3.38 DefoamerFoamaster 75 0.25 0.20 Surfactant Carbowet 109 0.87 0.54 BiocidePolyphase 678 0.17 0.09 Biocide Mergal K12N 0.25 0.16 Freeze/ThawAdditive, Prilled Urea 2.51 1.27 Blowing Agent Dispersant Orotan 731 dp0.34 0.35 Color Pigment Dispersion Phthalo Blue - 0.30 0.17 PlasticolorsMicrospheres Expancel 909 0.92 41.23 DET 80 d15 Functional Filler/SmokeAluminum Trihydrate 6.70 1.88 and Flame Retardant SB432 MineralThickener Laponite RDS 2.31 0.74 Expandable Graphite Asbury 3626 6.702.00 ASE Thickener Viscoatex 730 0.50 0.32 Tertiary Amine pH ModifierVantex T 0.70 0.49 100 100

Table 6 is an example formula for a product having a density of 0.99g/cm³. This formula is an aqueous formulation capable of over 60%compression. This formula exhibits fast skinning and fast cure for anaqueous sealant. It may be used as a moisture resistant, fire retardantsealant for building penetrations, cracks, and gaps.

TABLE 6 Raw Material % % Category Raw Material Weight Volume StyrenatedAcrylic Rhoplex 2019RX 30.99 29.70 Polymer Acrylic Polymer RhoplexEC-3000 30.65 29.40 Diluent Water 3.00 2.97 Defoamer Foamaster 75 0.260.30 Surfactant Carbowet 109 0.68 0.62 Plasticizer Santicizer 148 1.701.65 Biocide Polyphase 678 0.07 0.06 Biocide Mergal K12N 0.16 0.15Freeze/Thaw Additive, Prilled Urea 1.36 1.01 Blowing Agent DispersantOrotan 731 dp 0.34 0.52 Color Pigment Phthalo Blue - 0.22 0.18Dispersant Plasticolors Microspheres Dualite E065-135D 1.36 20.81 FillerMagnapearl 1000 2.04 0.67 Functional Filler/Smoke Aluminum Trihydrate25.88 10.68 and Flame Retardant SB432 HASE Thickener Polyphobe 115 0.310.28 ASE Thickener Viscoatex 730 0.16 0.15 Teriary Amine pH ModifierVantex T 0.82 0.84 100 100

FIG. 1 provides a flowchart 100 illustrating an example method forproducing the composition. At 102, the liquids are added to an emptyvessel. Such liquids may include, for example: water, surfactant,dispersant, defoamer, and biocides. At 104, any additives are added tothe vessel. Such additives may include, for example: anti-freeze agent,dye or pigments, plasticizer, coalescing agents, or any other additivesdiscussed herein. At 106, the mixing sweep blades are activated. In someembodiments, a vacuum is activated if the polymer is dosed using avacuum to pull the material into the vessel. The vacuum dissipates asthe polymer is loaded. Otherwise, the polymer is dosed from a weighhopper into the vessel.

At 108, the polymer is added to the mix until about half of the polymeris dosed, then a disperser is activated. At 110, the remaining polymeris dosed and the vacuum is activated (or reactivated) to approximately28 inHg. At 112, the microspheres are added to the mixture. In someembodiments, this is achieved by using a weigh hopper filled withmicrospheres. The weigh hopper is on load cells that show the totalweight. The microspheres are loaded into the mixer by loss of weight(that is, by subtracting the required weight in the formulation from thetotal weight in the hopper) and using a peristaltic pump to dose themicrospheres into mixer. Once the dosing is complete, the peristalticpump is deactivated and the pump valves at the hopper and mixer areclosed. Due to their light-weight nature, the microspheres may form acloud in the head space of the vessel. The composition is mixed whilethe microspheres settle. In some embodiments, the microspheres are dosedusing a closed system to avoid irritating microsphere dust cloud.

Once the microspheres are clear from the head space and mixed into theliquids so there is adequate headspace in the vessel, the vacuum vent isreleased, the mixer is deactivated, and dry materials are added at 114.Then the sweep blades and disperser are activated. Examples of such drymaterials may include: fillers such as mica, aluminum trihydrate, kaolinclay, magnesium hydroxide, aluminum phosphate, aluminum polyphosphate,fillite, calcium carbonate, talc, silica, or others or a combination ofsome depending on final product performance properties.

At 116, a vacuum is generated to wet out the dry materials as theproduct mixes. In some embodiments, this process causes the product torise in the mixer. If the product rises beyond a desired level, thevacuum may be released and reactivated as needed. In some embodiments,the product is mixed for approximately ten minutes.

At 118, the vacuum is released and the thickener is added to the mixturewhile the sweep blades and disperser are running. At 120, the pHmodifier is added, the mixer is closed and a vacuum is generated forapproximately twenty minutes to ensure the product is deaerated forimproved film formation in the finished product. In some embodiments,the thickener, water, and/or pH modifier may be adjusted as needed.

It should be appreciated that the above method is an example, and may bemodified to achieve different performance parameters. Such modificationsmay be made to the order in which the materials are added, specificchemical additives used, timing related to opening and closing themixer, use of the vacuum, and timing of the sweep blades and disperser.

In some embodiments, the disclosed composition may be packaged using afiltering process to remove any particles or agglomerates that couldclog spray apparatus nozzle tips. In one embodiment, for example, afterthe finished product is mixed, it is drawn through a sieve with a vacuumpump. Another embodiment for filtering particles or agglomerates thatcould clog spray apparatus nozzle tips includes using a continuousfiltering system with internal sweeps that remove the particles oragglomerates from the screen continuously and can be purged regularly asneeded to allow the incoming filter pressure to remain close to theoutgoing filter pressure. The disclosed filtering processes offer animprovement over other filtering methods, such as using a sock filter,which becomes quickly backed up with finished product due to thecompressible nature of the composition which will quickly stop theproduct from flowing through by deforming and compacting themicrospheres in the mastic inside the sock, which will build pressureuntil the sock is breached. Without the ability to filter, the masticcannot be applied in a spray application.

A number of additional and alternative embodiments of the presentdisclosure may be provided without departing from the spirit or scope ofthe present disclosure as set forth in the aspects provided herein.These various embodiments are believed to be understood by one ofordinary skill in the art in view of the present disclosure.

What is claimed is:
 1. A method of manufacturing a sealant composition,the method comprising: mixing a liquid and additives, wherein thesealant composition comprises from about 0 vol % to about 10 vol % ofthe additives; dosing a polymeric dispersion into the mix of liquid andadditives, wherein the sealant composition comprises up to about 80 vol% of the polymeric dispersion; and dosing a density modifier, whereinthe sealant composition comprises from about 20 vol % to about 65 vol %of the density modifier.
 2. The method of claim 1, further comprising:adding dry materials; wetting out the dry materials while mixing thesealant composition; adding a thickening agent and pH modifier to thesealant composition; and deaerating the sealant composition.
 3. Themethod of claim 1, further comprising filtering the sealant compositionfor use in a spray application.
 4. The method of claim 3, whereinfiltering the sealant composition comprises drawing the sealantcomposition through a sieve with a vacuum pump.
 5. The method of claim3, wherein filtering the sealant composition comprises continuouslysweeping the sealant composition through a sieve.
 6. The method of claim1, wherein the density modifier includes microspheres comprising anouter shell encapsulating a gas.
 7. The method of claim 1, furthercomprising packaging the sealant composition in one or more of aerosolcans, cartridge tubes, foil tubes, squeeze tubes, buckets, orcombinations thereof.
 8. The method of claim 1, wherein the sealantcomposition is configured to have one or more of the attributes selectedfrom a group consisting of: air blocking, structural reinforcement,moisture resistance, condensation control, thermal resistance, smokeresistance, flame resistance, softness, viscosity build, reducedshrinkage, altered density, changed electro-conductivity, improved scrubresistance, reduced tack, altered optical properties, alteredpermeability, color, vibration dampening, acoustical absorption, andinsulating.
 9. The method of claim 1, wherein the one or more additivesare selected from the group consisting of mica, aluminum trihydrate(ATH), magnesium hydroxide, expandable graphite, ammonium polyphosphate,ammonium phosphate, urea, sodium silicate, and combinations thereof. 10.The method of claim 1, wherein the sealant composition is configured forapplication using a brush, trowel, spray can, airless sprayer, orcombinations thereof.
 11. A method of manufacturing a sealantcomposition, the method comprising: mixing a liquid and additives in avessel including mixing sweep blades, wherein the sealant compositioncomprises from about 0 vol % to about 10 vol % of the additives;activating the mixing sweep blades of the vessel to stir the liquid andadditives; activating a vacuum configured to draw a polymeric dispersioninto the vessel; dosing a polymeric dispersion into the mix of liquidand additives by the vacuum, wherein the sealant composition comprisesup to about 80 vol % of the polymeric dispersion; dosing a densitymodifier comprising microspheres into the vessel via a peristaltic pump,wherein the sealant composition comprises from about 20 vol % to about65 vol % of the density modifier; permitting the mixing sweep blades tocontinue stirring while the density modifier settles into the polymericdispersion from a headspace of the vessel; and deactivating the vacuumand deactivating the mixing blades.
 12. The method of claim 11, furthercomprising: adding a first dry material following the deactivating themixing blades; and reactivating the mixing blades to stir the liquid,additives, density modifier, and first dry material.
 13. The method ofclaim 11, wherein a cured state of the sealant composition is aclosed-cell air barrier thermally insulating foam and has a first curedvolume and is compressible from the first cured volume to a second curedvolume when under a pressure, wherein the cured state of the sealantcomposition is configured to return to the first cured volume after thepressure is removed, and wherein an aqueous uncured state of the sealantcomposition has a first aqueous volume and is capable of beingcompressed from the first aqueous volume to a second aqueous volume thatis less than the first aqueous volume.
 14. The method of claim 13,wherein the polymer dispersion comprises an elastomeric polymer suchthat the sealant composition is an elastomeric mastic.
 15. A method ofmanufacturing a sealant composition, the method comprising: providing atleast about 60 wt % of an acrylate-acrylonitrile copolymer; andintroducing, by a closed mixing system, into the copolymer, at leastabout 1 wt % of a pre-expanded compressible microspheres, wherein acured state of the sealant composition is a closed-cell air barrierthermally insulating foam and has a first cured volume and iscompressible from the first cured volume to a second cured volume whenunder a pressure, wherein the cured state of the sealant composition isconfigured to return to the first cured volume after the pressure isremoved, and wherein an aqueous uncured state of the sealant compositionhas a first aqueous volume and is capable of being compressed from thefirst aqueous volume to a second aqueous volume that is less than thefirst aqueous volume.
 16. The method of manufacturing a sealantcomposition according to claim 15, wherein the sealant compositionfurther comprises: (i) at least about 3 wt % of a diluent, (ii) at leastabout 0.1 wt % of a defoamer, and (iii) at least about 1 wt % of asurfactant.
 17. The method of manufacturing a sealant compositionaccording to claim 16, wherein the sealant composition furthercomprises: (iv) at least about 0.1 wt % of a first biocide, (v) about0.2 wt % of a second biocide, (vi) at least about 2 wt % of a freezeagent, a thaw agent and/or a blowing agent, (vii) at least about 0.9 wt% of a dispersant, (viii) at least about 1.5 wt % of a thickener, and(ix) at least about 2 wt % of a pH modifier.
 18. The method ofmanufacturing a sealant composition according to claim 17, wherein thesealant composition further comprises: (x) at least about 0.3 wt % of acolor pigment dispersion, (xi) at least about 3 wt % of a first flameretardant, (xii) at least about 6 wt % of a first filler, and (xiii) atleast about 15 wt % of a second flame retardant.
 19. The method ofmanufacturing a sealant composition according to claim 15, comprisingintroducing the pre-expanded compressible microspheres under vacuum. 20.The method of manufacturing a sealant composition according to claim 15,comprising introducing the pre-expanded compressible microspheres by aperistaltic pump of the closed mixing system.
 21. The method ofmanufacturing a sealant composition according to claim 15, wherein thesealant composition comprises: at least about 40 vol %acrylate-acrylonitrile copolymer; and at least about 44 vol %pre-expanded compressible microspheres.
 22. The method of manufacturinga sealant composition according to claim 21, wherein the sealantcomposition further comprises: (i) at least about 2 vol % of a diluent,(ii) at least about 0.1 vol % of a defoamer, and (iii) at least about0.8 vol % of a surfactant.
 23. The method of manufacturing a sealantcomposition according to claim 22, wherein the sealant compositionfurther comprises: (iv) at least about 0.05 vol % of a first biocide,(v) about 0.1 vol % of a second biocide, (vi) about at least 1 vol % ofa freeze agent, a thaw agent and/or a blowing agent, (vii) at leastabout 0.5 vol % of a dispersant, (viii) at least about 0.9 vol % of athickener, and (ix) at least about 1 vol % of a pH modifier.
 24. Themethod of manufacturing a sealant composition according to claim 23,wherein the sealant composition further comprises: (x) at least about0.2 vol % of a color pigment dispersion, (xi) at least about 1 vol % ofa first flame retardant, (xii) at least about 1.6 vol % of a firstfiller, and (xiii) at least about 4 vol % of a second flame retardant.